Transport vehicle fleets rely on constant readiness if they want to operate economically. Axle and chassis manufacturer BPW knows how to avoid unforeseen damage and downtime. For example, with the iC Plus trailer chassis in combination with the software solution from subsidiary Idem Telematics. The iC Plus Retrofit upgrade solution was also presented at this year's Conference Days.
Why do trailer downtimes occur?
"In the transport industry, there's actually nothing more expensive than a vehicle that stands in the workshop, breaks down on the roadside, incurs fines due to poor maintenance, or, in the worst case, causes an accident,"
BPW product manager Caren Freudenberg began her presentation. The reasons can be pinpointed to several factors such as insufficient air pressure in trailer tires, which are also heavily stressed by different load weights and road conditions. The pressure difference accelerates tire wear and can potentially become a traffic risk. In any case, tire punctures accounted for two-thirds of the most common breakdown reasons, according to Freudenberg.
Deteriorating braking performance can also impair the operation of the vehicles to the point of standstill. Finally, mandatory maintenance cycles and inspections also keep the vehicles from operating fully.
Savings potential
The suspension expert sees countermeasures in targeted maintenance planning, which can increasingly be achieved using intelligent algorithms. BPW, for instance, can already quite accurately assess the condition of trailers this way, issue warnings, and initiate maintenance measures in advance, also known as Predictive Maintenance.
Freudenberg explained the solutions using certain functions of the latest, first introduced in 2023 "digital" axle iC Plus. For example, the Brake Performance Monitor shows the brake condition based on the data collected with the axle. This way, the brake can be specifically optimized through continuous monitoring. This works via integrated sensors that monitor the wear of the brake pads.
The axle load indicator also provides comprehensive data: this time about the load. The values are then displayed in the telematics system from Idem Telematics. Monitoring ensures that there is no overloading. And the monitoring goes even further: it can almost in real-time
determine when the vehicle was loaded and unloaded. The conditions under which a warning should be issued can be individually configured.
One of the main points, however, remains the tire pressure control, which is legally mandatory for new commercial vehicles from July 2024 according to UN ECE R 141. The iC Plus chassis generation can not only be equipped with the Tire Pressure Monitoring System (TPMS) but also with a Tire Pressure Regulating System (TPRS) that keeps the pressure always in the optimal range. BPW calls this AirSave tire pressure regulation system.
Important: TPMS system
Here the advantage of the iC Plus chassis is evident: Normally, the mandatory tire pressure control system TPMS needs to be connected to the EBS (Electronic Brake System) with an additional device. With iC Plus this additional component is eliminated since the TPMS or, as a comfort system, the AirSave sensors can be used for this purpose. The sensors connect with the telematics so that fleet managers can keep an eye on the data at any time via the Cargofleet telematics platform.
BPW advertises with the significant fuel savings and reduced tire wear for its AirSave system and promises savings of up to 890 euros and 655 kilograms of CO2 per year.
Additionally, BPW has developed a digital maintenance calendar for the Cargofleet portal, which should make planning workshop visits easier for managers and also contains maintenance history information.
Delivery scope of iC Plus
The standard BPW axle with its regular 9 t unit and optionally ECO Air or Airlight II suspension, as well as disc or drum brakes, is transformed into an iC Plus axle through specific function enhancements. For instance, by adding a brake pad wear sensor available for both brake types. The package of components that upgrade the axle to an iC Plus component also includes a connection for all common EBS. Included in the package is the basic or pro version of the telematics base equipment for trucks and vehicle fleets: the so-called TC Trailer Gateway enables entry into telematics and offers a modular,
flexibly expandable system of data collection solutions. Access to the Cargofleet 3 portal is also included. Optionally, the TPMS or TPRS (AirSave) can be added.
Cargofleet telematics portal: Intelligent maintenance
The telematics platform, through which the recorded data can be viewed and analyzed, was presented by expert Heiko Boch, Head of Product Management at Idem Telematics.
The end device is installed in the trailer as is already known from trucks and records the vehicle data. The vehicle is localized via GPS. All information is collected at the central station via the classic mobile radio system, where the states can be analyzed and displayed clearly via Cargofleet. This way, the hauliers have all the data about the vehicle condition and the location of the trailers at a glance at any time. "With the trailer telematics, we have continuous monitoring," said Boch.
The Cargofleet portal can also be used for individual alarm outputs – it can be set, for example, who is informed under what circumstances (e.g., temperature exceedance) and in what way (e-mail, SMS, etc.). Reports are also created according to various parameters. Maintenance information can also be included for individual planning. Boch:
"After maintenance has been carried out, the result can be documented so that the cycle closes: the maintenance cycle begins anew, and I have a continuous documentation of my vehicle maintenance."
According to Boch, the application can also be used across brands thanks to open interfaces. "We integrate other systems." Regardless of the vehicle types – trailers, trucks, or others – the systems are integrable and, conversely, the trailer telematics data can be integrated into other systems. "We do not have any hesitation with competitors." The question is only what the respective system is then capable of evaluating from the adopted data. The use could be difficult, for example, with the Performance Monitor, but a classic location tracking, for instance, is certainly possible.
Inbound and outbound interfaces exist with the manufacturers in the commercial vehicle sector, Boch confirms: We offer the integration of truck systems from the manufacturers. This way, truck
and trailer combinations can also be depicted together. "Similarly, we can also integrate telematics data from trailer manufacturers and also provide data to these systems."
Upgrade system iC Plus Retro-Fit
Not only for newly equipped trailers, BPW also offers an iC Plus solution called iC Plus Retro-Fit for existing commercial vehicles so that fleet managers can benefit from all the advantages for their existing vehicles and test the solution in the fleet. The retrofit solution provides a cost-effective way to integrate into the fleet: "Vehicles and their performance are monitored and optimized because you recognize early when maintenance is due," said Freudenberg.
BPW provides an amortization calculator on its website that can calculate individual savings possibilities.
Artificial Intelligence (AI) integrated
In doing so, the software uses certain functionalities of Artificial Intelligence. For example, in the Brake Performance Monitor: current braking actions are monitored and trends and quality statements are made through corresponding evaluations, as Boch explains. Similar systems to those known from Copilot and ChatGPT are used in the Cargofleet Assistant. However, only the fleet's data is used, and this is not passed on elsewhere. All data remains in the Cargofleet system, where it is evaluated with AI (Artificial Intelligence) accordingly. An extension of these AI functions is currently being planned.
The presentation, with additional illustrative information on the solution, as well as all other recordings from the Conference Days, is available on the website after registration for the sessions to view.
Commercial vehicle axle and chassis manufacturer BPW (Bergische Patentachsenfabrik Wiehl), officially known today as Bergische Achsen KG, celebrates its 125th company anniversary this year. The commercial vehicle portfolio includes axles, components such as brakes, telematics applications, and other accessories like the Airsave tire pressure monitoring system. The BPW Group, headquartered in Wiehl, North Rhine-Westphalia, employs around 6,800 people. There is a worldwide service network with 3,200 service partners, and partnerships have been established with, for example, ADAC TruckService. The BPW Group also includes the Munich-based systems partner and software specialist Idem Telematics, which specializes in connectivity solutions and management systems for
